Two-stage process of fabricating individual shapes



J. W. SMITH Oct. 15, .1929.

TWO-STAGE PROCESS OF FABRICATINGINDIVIDUAL SHAPES s Sheets- Sheet 1 Filed Sept. 5. 1926 i mm ATTORNEYS.

Oct. 15, 1929. w, SMITH 1,731,277

TWO-STAGE PROCESS OF FABRICATING INDIVIDUAL SHAPES Filed Sept. 3, 1926 5 sheetssheet 2 a FJG 1/;

WITNESSES v INVENTOR:

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ATTORNEYS.

Oct. 15, 1929.

TWO-STAGE IROCESS OF FABRICA'IING INDIVIDUAL SHAPES Fil ed Sept. s, 1926 s Sheets-Sheet 5 FIC3Z m.

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WITNESSES ORNEYS.

J.- WISMITH 1,731,277

Patented Oct. 15, 1929 UNirED STATES PATENT OFFICE JOHN W. SMITH, OF PHILADELPHIA, PENNSYLVANIA TWO-STAGE PROCESS OF FA-BRICATING INDIVIDUAL SHAPES Application filed September 3, 1928. Serial No. 133,432.

This invention relates to a two-stage process of fabricating individual shapes which embodies a first stageprocess of metering I process there may be included a cleaning and non-oxidizing step which is to be used when a fine surface finish is required to equal the specification commonly required in cold rolling of steel.

The two-stages of forging and rolling may be completed with one heat in some cases, while in other cases re-heating between the first and second stage is made use of to advantage.

In die forging the hub cavity is filled by confining the metal within the dies, which results in a very high internal pressure brought about by increasing the resistance at the splash. A temperature of 1800 F. to 2000 F. would be considered a normal condition for filling hub cavities as illustrated in typical examples. The die forging features are fundamental to the first stage in my process.

A continuous processof forging and rolling in one heat requires low temperature rolling for the second stage. This process of expanding and reducing to thin section cannot be eifected by die forging andis a fundamental of the second stage. i

Even though it be necessary to supply heat between the two stages, low temperature finishing of the article by rolling is still an important factor from a standpoint of cost and finish. A rolling temperature of 1100 F. to 1300 F. is considered suitable.

One of the chief advantages of this novel process is the minimum amount of heat rev14:. Such quired in fabricating the raw material into a finished-article.

WVith the foregoing objects in view this invention consists in the co-ordination of a fundamental forging stage under pressure control, with a furtherfundamental rolling stage effective to produce a predetermined zonal'cthickness.

The accompanying drawings typically illustrate means for practically carrying out this invention, as well as typical examples of the resultant products, while the appended claims define those features believed to be novel in the art.

' In the drawings: I Fig.1 is an assemblyview of co-ordinated apparatus suitable forcarrying out my novel process, parts being in section, and others relatively placed,f or the sake of clearness.

Fig. II is a sectional view taken as indicated by'the arrowed lines IIII in the preceding illustration- Fig. III is a sectional view of adisk wheel blank formed by the first stage operation.

Fig. IV is a similar view illustrative of the first and second stage operations.

Fig. V is a corresponding. view showing the finished disk wheel. Figs. VI, VII and VIII, are corresponding views illustrative of a variation in the article producible by my two-stage process.

Referring more in detail to the drawings, a conventional progressive-heating furnace is designated by the numeral 5, the same being adapted to heat billets 6, and intermittently advance them on to a table 7, from which they are, preferably, mechanically transferred to feed rollers 8. These feed rollers 8 are, conveniently, co-ordinated by a worm-drive 9 and tooth gear 10 with any suitablesource of rotary motion-not shown.

Q As indicated on Fig. I, each successive billet 6 is fed from the furnace 5, by way of a guide 11, to an appropriate metering and severing means-12, associated with formative dies 13 effective to produce hubbed blanks a metering-severing-formative means constitutes the subject-matter of an earlier application for patent, filed by me'the 7th day of June I926, under Serial Number 114,241; but, any other suitable forging .means may be employed, without departing from the scope of this invention, provided the same is of a character adapted to produce consecutive individual shapes from bar material.

From the formative dies 13 the successive hubbed blanks 14 may be conveyed by any suitable means-not showninto a hot cleaning chamber 15, for the removal of scale. This chamber 15 can be either of the sand blast, brushing, tumbling, or any other type, effective to remove scale with the least possible loss of heat.

WVhen the cleaning means referred to in the preceding paragraph is employed, each consecutive hubbed blank 14 is automatically or otherwise-progressed therefrom into an approved furnace 16 serving to prevent oxidation of the heated blank. This furnace 16 embodies a bath 17 containing suitable salt -or salts18, in a molten condition, through which the hubbed blanks 14'are advanced by means of a pronged conveyor 19. Guidance for the hubbed blanks 14 is afforded by a longitudinal race 20 medially of the bath 7, while the furnace inlet'and outlet chutes are, respectively, designated by the numerals Each consecutive hubbed blank 14, as it passes from the outlet chute 22, is received by a forked member 23 manuallyor otherwiseactuated by a hand lever 24 functional to transfer said blank to one of the trunnions 25 of a rotary feeder 26 for progression to appropriate rolling means 27. This rolling means 27 serves to reduce the disk zone 28 to tapering gaugeas shown in Fig. IV, or to an even gauge-as shown in Fig. VII; while 29 designates a discharge chute for the finished disk-wheel 30-Figs. V and VIII. Such a rolling means as above briefly referred to forms the subject-matter of an earlier application for patent, filed by'me 'on the 15th day of May, 1924, under Serial Number 713,425; but any other convenient rolling means effective to produce the requisite gauge and finish of the disk zone 28 may, obviously, be employed.

From the foregoing it is thought the novel two-stage process will be quite clear to those acquainted with the art. However, it is desired to particularly stress the same by specific reference to FigsIII and VI, which illustrate the product of the first stage or die forging under pressure control; while Figs. IV and VII, show the additional result of the second stage or rolling operation effective to produce the proper distribution and thickness of material in the disk zone 28. On the other hand Figs. V and VIII, show, by way of typical examples, the possible but not so restrictedfinal shape. Thus it' is self evident that my invention is predicated to the combination of hitherto separate and distinctive fundamental operations into a coordinated two-stage material fabricating process.

Having thus described my invention, I claim:

1. The two-stage process of fabricating metal bar material into individual disk wheels which comprises a fundamental stage of severing the bar by forging to provide hubbed blanks, and a co-ordinated fundamental rolling-stage effective to expand the web portion of each said hubbed blank to the required diameter and reduce the thickness to the required gauge.

2. The two-stage process of fabricating heated metal bar material into individual disk wheels which comprises a fundamental metering-and-forging stage to sever the bar and produce successive hubbed units having concentric webs, and a fundamental rollingstage effective to expand the aforesaid concentric web portion to predetermined diameter. I

3. Tlfe two-stage process of fabricating metal billets into individual forgings of the class described which comprises a fundamental step of severing the bar by forging to produce hubbed blanks of predetermined size, and a co-ordinated fundamental rolling stage effective to expand the disk zone of said blanks to the required diameter.

4. The two-stage process of fabricating metal bar material into individual forgings of the class described which comprises a fundamental step of severing the bar by forging to produce hubbed blanks of predetermined size, and a co-ordinated fundamental rollingstage effective to expand the web portion of said hubbed blank to the required diameter and reduce the thickness to the required gauge.

5. A continuous two-stage process of fabricating metal billets into individual forgings of the class described which comprises a fundamental step of severing the bar by forging to produce hubbed blanks of predetermined size, and a co-ordinated fundamental rolling stage effective to expand the disk zone of said blanks to the required diameter.

6. A continuous two-stage process of fabricating metal bar material-into individual forgings of the class described which comprises a fundamental stage of severing the bar by forging to produce hubbed blanks of predetermined size, and a co-ordinated fundamental rolling-stage effective to expand the web portion of said hubbed blank to the required diameter and reduce the thickness to the required gauge.

step.

8. A two-stage process, as claimed in claim 3, of fabricating disk forgings of the class described characterized by an intermediate step serving to prevent oxidation of the heated units.

In testimony whereof, I have hereunto signed my name at Philadelphia, Pennsylvania, this 31st day of August, 1926.

JOHN WV. SMITH. 

